Pressure sealed electrical connection interface

Abstract

Components and systems include devices for implementing downhole splice connections within a wellbore. In some embodiments, a downhole splice connector includes at least one connector body having an inner diameter defining a cavity within which at least one connector receptacle is disposed, and at least one conductive center pin disposed within the at least one connector receptacle. The downhole splice connector further includes at least one pressure sleeve annularly disposed between an inner diameter of the connector body and an outer diameter of the center pin, such that a pressure barrier is formed between an outer diameter of the pressure sleeve and an inner diameter of the connector body and a pressure barrier is formed between an inner diameter of the pressure sleeve and an outer diameter of the center pin.

What is claimed is: 
     
       1. A downhole splice connector comprising:
 a first connector body having a first connector sleeve defining a first cavity, the first cavity extending from a first connector receptacle positioned within the first connector body to a first weld joint; 
 a second connector body having a second connector sleeve defining a second cavity, the second cavity extending from a second receptacle positioned within the second connector body to a second weld joint, 
 a splice interface axially disposed between and physically coupling the first connector body with the second connector body, the splice interface comprising a middle sleeve having a first end coupled to the first connector body at the first weld joint and having a second end coupled to the second connector body at the second weld joint, 
 a conductive center pin disposed within and extending axially through the splice interface, the conductive center pin having a first pin end extending into the first cavity of the first connector sleeve and a second pin end extending into the second cavity of the second connector sleeve; and 
 a pressure sleeve annularly disposed between an inner diameter of the splice interface and an outer diameter of the conductive center pin, such that a pressure barrier is formed between the first cavity of the first connector body and the second cavity of the second connector body. 
 
     
     
       2. The downhole splice connector of  claim 1 , wherein the pressure sleeve comprises a polycrystalline or amorphous material having at least one of a crystalline region and an amorphous region. 
     
     
       3. The downhole splice connector of  claim 1 , wherein the pressure sleeve comprises a ceramic glass sleeve and the pressure barrier includes:
 a first glass-to-metal joint formed between the outer diameter of the pressure sleeve and an inner diameter of the splice interface; and 
 a second glass-to-metal joint formed between an inner diameter of the pressure sleeve and the outer diameter of the conductive center pin. 
 
     
     
       4. The downhole splice connector of  claim 1 ,
 wherein the first connector body includes a first end coupler configured to mechanically fasten to a first coupling of a first line conductor to be coupled to the first connector body; and 
 wherein the second connector body includes a second end coupler configured to mechanically fasten to a second coupling of a second line conductor to be coupled to the second connector body. 
 
     
     
       5. The downhole splice connector of  claim 1 , wherein the first connector body, the second connector body, and the splice interface comprise a steel alloy material. 
     
     
       6. The downhole splice connector of  claim 1 , wherein the pressure sleeve is formed from an electrically insulative material and is configured to electrically insulate the conductive center pin from the middle sleeve. 
     
     
       7. The downhole splice connector of  claim 1 , further comprising:
 a first cylindrical groove disposed around a first end of the pressure sleeve proximate an inner axial end of the first connector sleeve; and 
 a second cylindrical groove disposed around a second end of the pressure sleeve proximate an inner axial end of the second connector sleeve. 
 
     
     
       8. The downhole splice connector of  claim 1 , wherein the conductive center pin is formed from an electrically conductive material comprising copper or a copper alloy, stainless steel, or a nickel alloy. 
     
     
       9. A downhole splice connector comprising:
 a first connector body having a first connector sleeve defining a first cavity, the first cavity extending from a first connector receptacle disposed within the first connector body to a first weld joint; 
 a second connector body having a second connector sleeve defining a second cavity, the second cavity extending from a second connector receptacle disposed within the second connector body to a second weld joint; 
 a middle sleeve axially disposed between and physically coupling the first connector body with the second connector body, the middle sleeve having a first end coupled to the first connector body at the first weld joint and a second end coupled to the second connector body at the second weld joint; 
 a first conductive pin partially disposed within the first connector body and partially disposed with the middle sleeve, the first conductive pin having a first pin receptacle end at one end of the first conductive pin and a first pin terminal end at an opposite end of the first conductive pin, wherein the first pin receptacle end is disposed within the first cavity and the first pin terminal end is disposed within the middle sleeve; 
 a second conductive pin partially disposed within the second connector body and partially disposed with the middle sleeve, the second conductive pin having a second pin receptacle end at one end of the second conductive pin and a second pin terminal end at an opposite end of the second conductive pin, wherein the second pin receptacle end is disposed within the second cavity and the second pin terminal end is disposed within the middle sleeve; and 
 a shrink ring comprising a conductive material, disposed within the middle sleeve, and annually disposed at the first pin terminal end of the first conductive pin and at the second pin terminal end of the second conductive pin, thereby forming an electrically conductive path between the first conductive pin and the second conductive pin. 
 
     
     
       10. The downhole splice connector of  claim 9 , further comprising:
 a first pressure sleeve annularly disposed between an inner diameter of the first connector body and an outer diameter of the first conductive pin, such that a first pressure barrier is formed between an outer diameter of the first pressure sleeve and an inner diameter of the first connector body, and a seconds pressure seal is formed between an inner diameter of the first pressure sleeve and an outer diameter of the first conductive pin; and 
 a second pressure sleeve annularly disposed between an inner diameter of the second connector body and an outer diameter of the second conductive pin, such that a third pressure barrier is formed between an outer diameter of the second pressure sleeve and the inner diameter of the second connector body, and a fourth pressure barrier is formed between an inner diameter of the second pressure sleeve and an outer diameter of the second conductive pin. 
 
     
     
       11. The downhole splice connector of  claim 10 , wherein the first pressure sleeve and the second pressure sleeve comprise a ceramic glass. 
     
     
       12. The downhole splice connector of  claim 10 , further comprising:
 a first cylindrical groove extending from an axial end of the first connector receptacle proximate the first weld joint, the first cylindrical groove disposed concentrically around at least a portion of the first pressure sleeve; and 
 a second cylindrical groove extending from an axial end of the second connector receptacle proximate the second weld joint, the second cylindrical groove disposed concentrically around at least a portion of the second pressure sleeve. 
 
     
     
       13. The downhole splice connector of  claim 9 , wherein the shrink ring is disposed between a pair of shrink ring collars and opposing portions of the first pin terminal end of the first conductive pin and the second pin terminal end of the second conductive pin. 
     
     
       14. The downhole splice connector of  claim 13 , further comprising an outer shrink ring disposed between the pair of shrink ring collars and the shrink ring. 
     
     
       15. The downhole splice connector of  claim 9 , wherein the first pin terminal end of the first conductive pin and the second pin terminal end of the second conductive pin are directly coupled in a male-to-female connection. 
     
     
       16. A downhole electrical connection apparatus comprising:
 an electric line disposed within a wellbore; and 
 a splice connection that electrically and physically couples a first segment of the electric line to a second segment of the electric line, said splice connection comprising:
 a first connector body having a first connector sleeve defining a first cavity, the first cavity extending from a first connector receptacle disposed within the first connector body to a first weld joint; 
 a second connector body having a second connector sleeve defining a second cavity, the second cavity extending from a second connector receptacle disposed within the second connector body to a second weld joint; 
 a middle sleeve axially disposed between and physically coupling the first connector body with the second connector body, the middle sleeve having a first end coupled to the first connector body at the first weld joint and a second end coupled to the second connector body at the second weld joint; 
 a first conductive pin partially disposed within the first connector body and partially disposed with the middle sleeve, the first conductive pin having a first pin receptacle end at one end of the first conductive pin and a first pin terminal end at an opposite end of the first conductive pin, wherein the first pin receptacle end is disposed within the first cavity and the first pin terminal end is disposed within the middle sleeve; 
 a second conductive pin partially disposed within the second connector body and partially disposed with the middle sleeve, the second conductive pin having a second pin receptacle end at one end of the second conductive pin and a second pin terminal end at an opposite end of the second conductive pin, wherein the second pin receptacle end is disposed within the second cavity and the second pin terminal end is disposed within the middle sleeve; and 
 a shrink ring comprising a conductive material, disposed within the middle sleeve, and annually disposed at the first pin terminal end of the first conductive pin and at the second pin terminal end of the second conductive pin, thereby forming an electrically conductive path between the first conductive pin and the second conductive pin. 
 
 
     
     
       17. The downhole electrical connection apparatus of  claim 16 , further comprising:
 a first pressure sleeve annularly disposed between an inner diameter of the first connector body and an outer diameter of the first conductive pin, such that a first pressure barrier is formed between an outer diameter of the first pressure sleeve and an inner diameter of the first connector body, and a seconds pressure seal is formed between an inner diameter of the first pressure sleeve and an outer diameter of the first conductive pin; and 
 a second pressure sleeve annularly disposed between an inner diameter of the second connector body and an outer diameter of the second conductive pin, such that a third pressure barrier is formed between an outer diameter of the second pressure sleeve and the inner diameter of the second connector body, and a fourth pressure barrier is formed between an inner diameter of the second pressure sleeve and an outer diameter of the second conductive pin. 
 
     
     
       18. The downhole electrical connection apparatus of  claim 16 , wherein the shrink ring is disposed between a pair of shrink ring collars and opposing portions comprising the first pin terminal end of the first conductive pin and the second pin terminal end of the second conductive pin. 
     
     
       19. The downhole electrical connection apparatus of  claim 16 , wherein the first pin terminal end of the first conductive pin and the second pin terminal end of the second conductive pin are directly coupled in a male-to-female connection. 
     
     
       20. The downhole electrical connection apparatus of  claim 16 , further comprising:
 a first seal groove and a first weld flange extending axially around an outer surface of the first connector body; and 
 a second seal groove and a second weld flange extending axially around an outer surface of the second connector body.